Power Plant Performance Optimization

FGS & Associates, LLC has proprietary software that can attain optimization of over 25 variables simultaneously to achieve superior plant performance. The software, System Optimization Analysis Program (SOAP), is an Artificial Neural Network based online optimization system developed by FGS. This, combined with FGS’s recognized experts in plant operations, provide a blending of experience and technology that is quite literally unmatched in the industry.

FGS can perform multiple plant objective optimization with such varied inputs as capacity, emissions limits or targets, safety, efficiency, temperatures, reliability, and cost.  This optimization is always accomplished between two and four weeks, never longer.  These techniques can be used for all types of fossil steam units and for all combustion turbine technologies and configurations.

The following are examples of past successful optimizations.

Case No. 1 – A 300 MW tangentially fired boiler performance optimization was performed in October 2003 and completed in 12 days.  The improvements included:

• Reduced NO_x by 20%

• Improved heat rate by 1%

• Reduced superheat and reheat spray flow by 50%

• Maintained 2% furnace wall surface O₂ to reduce corrosion

New control parameters were established, and operators were instructed in the changes in order to maintain long-term performance.  Fuel savings alone exceeded project costs in six months.

Case No. 2 – A 350 MW wall fired boiler performance optimization was performed in October 2003 and completed in 10 days.  The improvements included:

• Heat rate improvement of 2%
• Reduced superheat and reheat spray flow by 70%
• Reduced superheat tube temperatures by 35^oF (reducing tube failures)

New control parameters were established, and operators were instructed in the changes in order to maintain long-term performance. Fuel savings alone exceeded project costs in four months.

Case No. 3 – A 300 MW tangentially fired boiler performance optimization was performed in July 2004 and completed in 14 days.  The improvements included:

• Heat rate improvement of 2.7%
• Eliminated reheat spray flow
• Reduced carbon-in-ash by 2%

New control parameters were established, and operators were instructed in the changes in order to maintain long-term performance.  Fuel savings alone exceeded project costs in three months.